This paper presents the design, development, and optimization of a 3D printed micro horizontal axis wind turbine blade made of PLA material. The objective of the study was to produce 100 watts of power for low-wind-speed applications. The design process involved the selection of SD7080 airfoil and the determination of the material properties of PLA and ABS. A structural analysis of the blade was carried out using ANSYS software under different wind speeds, and Taguchi's L16 orthogonal array was used for the experiments. The deformation and equivalent stress of the PLA material were identified, and the infill percentage and wind speed velocity were optimized using the moth-flame optimization (MFO) algorithm. The results demonstrate that PLA material has better structural characteristics compared to ABS material. The optimized parameters were used to fabricate the turbine blades using the fusion deposition modeling (FDM) technique, and they were tested in a wind tunnel.

Department of Electrical and Electronics Engineering Varuvan Vadivelan Institute of Technology Tamil Nadu 636701 India

Department of Machining Assembly and Engineering Metrology Faculty of Mechanical Engineering VSB Technical University of Ostrava 708 00 Ostrava Czech Republic

Department of Mechanical Engineering Anna University Regional Campus Tirunelveli 627007 India

Department of Mechanical Engineering Vel Tech Rangarajan Dr Sagunthala R and D Institute of Science and Technology Avadi 600062 India

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